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TECHNICAL MANUAL MT044

6

COMMISSIONING

Commissioning must be carried out by adequately trained personnel.
During the commissioning activities, the personnel not strictly necessary must be ordered away and the no-go
area must be properly signalled (signs, barriers, etc.).
Check that the settings of the apparatus are those requested; if necessary, reset them to the required values in
accordance with the procedures indicated in the manual.
When commissioning, the risks associated with any discharges into the atmosphere of flammable or noxious
gases must be assessed.
In installations in natural gas distribution networks, the risk of the formation of explosive mixtures (gas/air) inside
the piping must be considered.

CONFORMITY TO DIRECTIVE 97/23/EC (PED)

Pressure regulator Norval is classified as fail open regulator according to the standard EN 334 therefore it is
categorized as

pressure accessory

according to directive 97/23/EC (PED).

The safety device in-line monitor is categorized as

safety accessory

according PED. The regulator Norval when

incorporating slam shut valve with pressure switche for overpressure is categorized as

safety accessory

according to PED, therefore it can be used both as pressure accessory and

safety accessory

to PED.

Conformity with Directive 97/23/EC and CE marking of pressure regulator and relevant accessory require
installation in the system with minimum requirements according to: EN 12286.

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Содержание NORVAL

Страница 1: ...PRESSURE REGULATOR NORVAL TECHNICAL MANUAL MT044 INSTALLATION COMMISSIONING AND MAINTENANCE INSTRUCTIONS E ...

Страница 2: ...TECHNICAL MANUAL MT044 2 Inlet pressure Outlet pressure NORVAL Issue February 2003 ...

Страница 3: ...ty shut off devices series when controlling overpressure and in line monitor system which includes a Norval with the function of active regulator and a 2 Norval with the function of in line monitor are classified as safety accessories according to clause 2 1 3 of art 1 of PED Production quality assurance module D by BUREAU VERITAS ID n 0062 Attestation d Approbation du Sistème Qualité N CE PED D F...

Страница 4: ...4 ...

Страница 5: ...he lifting gear is adequate for the loads to lift lifting capacity and functionality The apparatus must be handled using the lifting points provided on the apparatus itself Motorised means must only be used by the persons in charge of them PACKING The packing for trasportation of equipment and of relevant spare parts are designed and shaped to avoid damage to any part during transportation warehou...

Страница 6: ...tworks the risk of the formation of explosive mixtures gas air inside the piping must be considered CONFORMITY TO DIRECTIVE 97 23 EC PED Pressure regulator Norval is classified as fail open regulator according to the standard EN 334 therefore it is categorized as pressure accessory according to directive 97 23 EC PED The safety device in line monitor is categorized as safety accessory according PE...

Страница 7: ...H MONITOR FUNCTIONS 21 5 0 START UP 22 5 1 GENERAL 22 5 2 GAS INPUT CONTROL OF EXTERNAL TIGHTNESS AND SETTING 24 5 3 COMISSIONING THE REGULATOR 24 5 4 COMMISSIONING THE REGULATOR WITH INCORPORATED I N SLAM SHUT 25 5 5 COMMISSIONING THE REGULATOR PLUS NORVAL IN LINE MONITOR WITH INCORPORATED I N SLAM SHUT VALVE 29 6 0 TROUBLE SHOOTING 32 6 1 REGULATOR 32 6 2 REGULATOR SLAM SHUT 34 7 0 MAINTENANCE 3...

Страница 8: ...8 ...

Страница 9: ...1 are spring actuated devices with control of the downstream pressure by means of an external sensing line 1 The downstream pressure is controlled by means of the equilibrium between the action of the spring 2 and the action exerted by the downstream pressure on the diaphragm 3 The movement is transmitted by the shaft 4 to the obturator 5 which moves perpendicularly to the gas flow direction Herme...

Страница 10: ...TECHNICAL MANUAL MT044 10 5 Pe 4 1 3 2 74 Pa Fig 1 ...

Страница 11: ...00 1950 2100 3150 2704910 AZURE 14 0 8 00 10 00 1800 2800 3000 4400 Springs characteristics SETTING RANGE in mbar Covers CodE Colour De Lo d i it Ø 630 Ø 495 Ø 375 Ø 375 TR DN DN DN DN DN DN DN 2 1 2 3 4 1 2 2 1 2 4 1 2 2 1 2 4 1 4 De Ø external diameter d Ø wire diameter i active coils Lo spring length it total coils 2702599 WHITE 100 6 0 10 5 12 5 12 14 5 2702790 YELLOW 100 6 5 11 5 13 5 14 18 2...

Страница 12: ...1200 1950 2100 3150 2704910 AZURE 14 0 8 00 10 00 1800 1050 3000 4400 De Ø external diameter d Ø wire diameter i active coils Lo spring length it total coils Springs characteristics SETTING RANGE in mbar Covers Code Colour De Lo d i it Ø 630 Ø 495 Ø 375 Ø 375 TR DN DN DN DN DN DN DN 2 1 2 3 4 1 2 2 1 2 4 1 2 2 1 2 4 1 4 2703380 GREEN 100 8 0 12 5 14 5 8 13 2703560 BLACK 100 8 5 12 0 14 0 12 21 270...

Страница 13: ...level and capable of supporting the weight of the regulator the inlet outlet flanges of the piping are parallel the inlet outlet flanges of the regulator are clean and the regulator itself has not been subject to damage during transport the piping upstream has been cleaned to expel residual impurities such as welding scale sand paint residues water etc The normally raccomended set up is 2 0 INSTAL...

Страница 14: ...TECHNICAL MANUAL MT044 14 INSTALLATION AT RIGHT ANGLES TAB 4 DETAIL OF MULTIPLE TAKE OFF Regulator Sensing line Control pressure gauge Bleed cock On Off valve ...

Страница 15: ...emselves must slope down towards the downstream piping with a slope of about 5 10 b the connectors on the piping must always be welded on the top of the piping itself and there must be no burr or inward protrusions in the hole in the piping NB WE RECOMMEND NOT TO PUT ON OFF VALVES ON THE IMPULSE TAKE OFFS TAB 5 The speed of the gas must not exceed the following values in the piping downstream from...

Страница 16: ...pect to the set point The different models of relief valves available are all based on the same operating principle which is illustrated below with reference to the valve VS AM 55 fig 4 It is based on the contrast between the thrust on the diaphragm 24 deriving from the pressure of the gas to control and the thrust from the setting spring 20 The weight of the mobile assembly the static thrust and ...

Страница 17: ...to the cock 6 and stabilise it at the desired value 3 check intervention of the relief valve and adjust it if necessary by turning the internal adjustment ring 14 appropriately clockwise to increase the set point anticlockwise to reduce it 3 1 2 INSTALLATION WITH ON OFF VALVE Fig 6 1 Close the on off valve 16 2 connect a controlled auxiliary pressure to the take off 17 and increase it slowly to th...

Страница 18: ...hich immediately blocks the gas flow if following some kind of failure the downstream pressure reaches the set point for its intervention or if it is operated manually The main characteristics of the slam shut device are design pressure 18 9 bar for all the components intervention with pressure increase and or decrease intervention accuracy AG 1 of the pressure set point for pressure increases 5 f...

Страница 19: ...ure increase when the Pa exceeds the set point the load on the diaphragm 21 of the control head B increases until it overcomes the resistance of the spring 14 This provokes the downward displacement of the shaft 18 which shifts the feeler 19 and releases the lever mechanism 20 by means of the cam 23 Intervention for a pressure decrease takes place as follows As long as the value of Pa stays above ...

Страница 20: ...6 00 500 900 500 900 1300 2800 2702065 AZURE 5 0 4 50 6 00 850 1200 850 1200 2500 5000 SETTING RANGE mbar Springs characteristics I N Fig 9 I N Fig 10 I N TR Fig 9 and fig 10 Code Colour De Lo d i it max min max min max min 2700338 WHITE 1 3 8 75 10 75 5 19 8 23 2700377 YELLOW 1 5 8 50 10 50 15 50 20 50 2700464 ORANGE 40 1 7 8 50 10 50 45 100 45 100 2700513 RED 15 2 0 8 50 10 50 70 140 70 140 2700...

Страница 21: ...ter precision in the regulated pressure and therefore an equally precise pressure intervention value without problems of interference with the main regulator Chamber A is subject to the downstream pressure Fig 11b 4 3 NORVAL FUNCTIONING AS A MONITOR The monitor is an emergency regulator whose function is to come into service instead of the main regulator when failure of the latter causes the downs...

Страница 22: ...ou must ensure that the conditions of use comply with the characteristics of the apparatuses These characteristics are recalled by the symbols on the specification plates applied to each apparatus We recommend actuating the opening and closing valves very slowly The regulator could be damaged by operations which are too fast 5 0 START UP TARGHETTE APPARECCHIATURE ...

Страница 23: ...onsidered as a separate apparatus with its own setting range Wh QmaxPemin maximum flow rate with minimum pressure at the pressure regulator inlet QmaxPemax maximum flow rate with maximum pressure at the pressure regulator inlet Cg experimental coefficient of critical flow AC regulation class SG closing pressure class AG intervention accuracy Wao range of intervention for the over pressure of slam ...

Страница 24: ...er In installations consisting of two lines we suggest commissioning one line at a time starting from the one with the lower set point known as the reserve line The set points of the apparatuses in this line will obviously deviate from those specified in the tables 7 and 8 Before commissioning the regulator you must check that all the on off valves inlet outlet any by pass are closed and that the ...

Страница 25: ...ety devices which intervene for maximum pressure slowly increase the auxiliary pressure and check the intervention value If necessary increase the intervention value by turning the adjustment ring 12 clockwise or anticlockwise to reduce the intervention value for safety devices which intervene for pressure increase and reduction slowly increase the auxiliary pressure and record the intervention va...

Страница 26: ...essure to keep under control Rest position A and B in communication B On devices without the push valve fig 15 we recommend connecting the control head separately to a controlled auxiliary pressure and repeating the operations described above Fig 15 Safety device Environment with the pressure to keep under control Chamber with controlled pressure ...

Страница 27: ...lever 4 open the downstream bleed cock 6 5 check on the pressure gauge 5 that the downstream pressure is at the desired regulator set point If it is not adjust the setting by means of the provided screw turning it clockwise to increase it and anticlockwise to decrease it 6 close the bleed cock 6 and check the closing pressure value 7 using a foam medium check the tightness of all the joints betwee...

Страница 28: ... Pas 15 15 Pas 19 19 Pas 24 24 Pas 30 30 Pas 60 60 Pas 80 80 Pas 110 110 Pas 200 200 Pas 400 400 Pas 800 800 Pas 1000 1000 Pas 2500 2500 Pas 4000 20 mbar Pas x 1 5 Pas x 1 4 Pas x 1 25 Pas x 1 15 25 mbar Pas 20 mbar Pas 30 mbar Pas 40 mbar Pas 100 mbar Pas 150 mbar Pas 300 mbar Pas 500 mbar Pas 1000 mbar Slam shut not available 10 mbar Pas 10 mbar Pas 20 mbar Pas 40 mbar Pas 60 mbar Pas 100 mbar P...

Страница 29: ... knob 1 pressed and for safety devices which intervene for maximum pressure slowly increase the auxiliary pressure and check the intervention value If necessary increase the intervention value by turning the adjustment ring 12 clockwise or anticlockwise to reduce it for safety devices which intervene for pressure increase and reduction slowly increase the auxiliary pressure and record the interven...

Страница 30: ...hat the downstream pressure has the established setting value If it does not adjust the setting by means of the special screw 74 turning it clockwise to increase its value and anticlockwise to reduce its value 8 trip the slam shut manually 9 connect the sensing line of the main regulator 10 very slowly open the slam shut valve by turning the provided lever 11 check on the pressure gauge 5 that the...

Страница 31: ...15 Pas 19 19 Pas 24 24 Pas 30 30 Pas 60 60 Pas 80 80 Pas 110 110 Pas 200 200 Pas 400 400 Pas 800 800 Pas 1000 1000 Pas 2500 2500 Pas 4000 Pas 5 mbar Pas x 1 15 Pas x 1 15 Pas x 1 15 25 mbar Pas x 1 8 Pas x 1 55 Pas x 1 4 Pas x 1 3 Pas x 1 16 30 mbar Slam shut not available 10 mbar Pas 10 mbar Pas 20 mbar Pas 40 mbar Pas 60 mbar Pas 100 mbar Pas 200 mbar Pas 300 mbar Pas 20 mbar Pas 30 mbar Pas 40 ...

Страница 32: ...must therefore train your maintenance personnel or avail yourself of the service centres officially authorised by us 6 1 TAB 9 REGULATOR FIG 17 Dirt Clean the parts subject to movement Anti pumping valve not suitable for the Adjust or replace the internal part particular type of installation Compensating diaphragm 29 worn Replace Incorrect assembly of diaphragm 20 Check Operating anomalies Setting...

Страница 33: ...nforced gasket 4 damaged Replace Shaft locked by incrustation during Clean start up Setting higher than spring limit Replace spring Pressure increase at Q 0 Diaphragm 20 ruptured Replace Incorrect assembly of diaphragm 29 Fix No sensing signal from take off Check Demand higher than regulator flow rate Replace Pressure drop No pressure upstream Check any line filter 6 1 TAB 9 REGULATOR FIG 17 PROBL...

Страница 34: ...ing the whole assembly Persistence of the cause which led to Decrease or increase the downstream pressure increase or decrease downstream pressure Rearming not possible Lever system broken or chipped Change the standard box containing the assembly outside the regulator N B If the slam shut has intervened close the inlet and outlet valve V1 and V2 on the line and discharge the pressure before carry...

Страница 35: ...d that the more important ones such as diaphragms are marked A set of wrenches is available as specified in table 11 For a proper maintenance the reccomended spare parts are unequivocally identified by labels indicating The No of assembly drawing SR of the apparatus for which the spare parts are suitable The position showed in the assembly drawing SR of the apparatus N B The use of non original sp...

Страница 36: ...TECHNICAL MANUAL MT044 36 7 2 NORVAL REGULATOR MAINTENANCE PROCEDURE Fig 17 ...

Страница 37: ...eping the diaphragm support pos fixed slacken the lock nut pos Remove it and then remove the spring support pos the diaphragm protection disc pos the diaphragm pos and the rubber gasket pos 11 Keeping the rod pos fixed remove the self locking nut pos 12 Remove the rod pos from the bottom part of the regulator body 13 Remove the diaphragm support pos and the spacer pos 14 Disconnect the sensing lin...

Страница 38: ...28 Keeping the rod pos fixed fully tighten the self locking nut pos 29 Proceeding slowly carry out vertical movements of the top of the rod to check that it moves properly 30 Reassemble the gasket pos the diaphragm pos the diaphragm protection disc pos and the spring support pos and screw in the lock nut pos 31 Check that the holes in the diaphragm and bottom cover match and keeping the diaphragm ...

Страница 39: ...TECHNICAL MANUAL MT044 39 7 3 NORVAL REGULATOR I N MAINTENANCE PROCEDURE Fig 18 ...

Страница 40: ...t pos the diaphragm protection disc pos the diaphragm pos and the rubber gasket pos 11 Keeping the rod pos fixed remove the self locking nut pos 12 Remove the rod pos from the bottom part of the regulator body 13 Remove the diaphragm support pos and the spacer pos 14 Disconnect the sensing line which connects the bottom cover pos to the downstream piping by unscrewing the taper seal connections 15...

Страница 41: ...o the downstream piping and fix the taper seal connections 41 Put back the slam shut obturator support pos along with the spring pos and the obturator pos 42 Fit back the intermediate flange pos along with the rod guide sleeve pos 43 Put back the lock ring pos the balancing diaphragm pos and the bushing pos 44 Put the bottom cover pos back in its original position with the sensing line take off tu...

Страница 42: ...ream side 54 Put back and fix the screws pos with a torque of 5 KG M 55 Put back the regulation spring pos with the top spring cover pos 56 Screw the spring holder plug pos as far as it goes 57 Put back the obturator gasket pos screwing in the gasket support pos manually as far as it goes and fix it with a sharp blow 58 Put back the bottom flange pos by means of the fixing screws pos 42 47 41 22 2...

Страница 43: ...TECHNICAL MANUAL MT044 43 7 4 MAINTENANCE PROCEDURE FOR THE NORVAL REGULATOR I N ER Fig 19 ...

Страница 44: ...s 8 Slacken the adjustment screw pos until it comes out 9 Unscrew and remove the spring holder plug pos 10 Remove the adjustment spring pos along with the top spring support pos 11 Slacken and remove the fixing screws pos 12 Remove the top cover pos 13 Keeping the diaphragm support pos fixed slacken the lock nut pos Remove it and then remove the spring support pos the diaphragm protection disc pos...

Страница 45: ...them in their slots 35 Fix the shaft guide pos to the regulator body 36 Fit the pressure control back on the regulator body 37 Secure this by screwing in the screws pos 38 Put back the retaining ring pos 39 Position the reset lever pos 40 Put back the retaining ring pos 41 Put back the slam shut cover pos 42 Fix the screws pos of the slam shut cover pos 43 Reconnect the sensing line which connects...

Страница 46: ...into its original position with the anti pumping valve at the downstream side 57 Put back and fix the screws pos with a torque of 5 KG M 58 Put back the regulation spring pos with the top spring cover pos 59 Screw the spring holder plug pos as far as it goes 60 Put back the obturator gasket pos screwing in the gasket support pos manually as far as it goes 61 Fix it with a sharp blow 62 Reassemble ...

Страница 47: ...om the vertical position towards the horizontal position until only the internal by pass is opened Then raise the lever completely to the re engage position Check the tightness of the reinforced gasket of the regulator 3 Open a bleed cock downstream from the regulator to create a small gas flow 4 Screw in the adjustment screw pos until the desired set point value is reached 5 Close the bleed cock ...

Страница 48: ... 5 G Ch 13 17 19 22 13 17 22 17 22 17 24 27 17 27 17 27 I Ch 6 5 x 100 L Cod 7999099 M ø 19 60 O Cod 7999045 7999047 7999049 NORVAL I N Type DN 1 and 1 1 4 1 1 2 and 2 2 1 2 and 3 4 6 8 8 13 19 8 13 19 8 17 19 8 19 23 8 10 17 19 8 10 17 19 A Ch 23 27 32 36 23 27 32 36 23 27 32 36 24 27 32 36 22 23 27 32 36 22 23 27 32 36 B L 300 D Ch 10 27 10 27 10 27 10 27 10 27 10 27 E Ch 5 5 5 4 5 4 5 4 5 G Ch ...

Страница 49: ...7 3 28 28 4 3 4 3 4 3 6 4 6 4 6 4 10 10 10 8 10 8 10 8 16 3 16 3 16 3 19 19 12 5 22 5 36 0 3 0 5 0 3 0 3 0 3 1 7 4 2 8 2 1 3 2 5 2 1 4 5 4 5 5 10 14 5 10 14 5 16 6 25 5 36 5 48 90 148 0 3 0 3 0 3 0 4 0 4 0 5 1 1 3 0 3 0 3 0 5 0 7 1 1 2 3 5 5 5 0 8 1 3 2 2 5 75 10 4 16 22 3 8 0 WEIGHT OF THE COMPONENTS 8 1 TAB 12WEIGHTOFTHECOMPONENTSINKG ...

Страница 50: ...TECHNICAL MANUAL MT044 50 9 0 LIST OF RECOMMENDED SPARE PARTS ...

Страница 51: ...TECHNICAL MANUAL MT044 51 NORVAL pression regulator ...

Страница 52: ...TECHNICAL MANUAL MT044 52 VERSIONS DN 4 DN 4 1 2 3 DN 1 3 Fig E Fig B ONLY COVERS Ø 375 OR Ø 375 TR REDUCED HEAD TR Fig C DN 4 6 8 Fig D Fig F DN 4 ...

Страница 53: ...Only Only 4 6 8 2 1 2 3 4 TR ø 375 TR 4 Reinforced gasket 1 1 1 1 1 9 Guide ring 2 2 2 2 2 20 Diaphragm 1 1 1 1 1 28 Gasket 1 1 1 1 1 29 Diaphragm 1 1 1 1 1 30 U ring 1 1 1 1 1 43 O Ring 1 1 1 1 1 58 O Ring 1 1 1 1 1 60 O Ring 1 1 1 61 O Ring 2 2 2 62 O Ring 2 2 2 66 O Ring 1 1 1 67 O Ring 1 1 1 70 O Ring 1 72 O Ring 1 1 85 O Ring 2 2 86 O Ring 1 1 87 O Ring 2 2 88 O Ring 1 1 89 O Ring 1 1 90 O Ri...

Страница 54: ...TECHNICAL MANUAL MT044 54 I N I N TR SLAM SHUT Fig G DN 1 3 Fig K DN 1 3 Fig H DN 4 6 8 Fig L DN 4 6 8 RESET LEVER RESET LEVER ...

Страница 55: ...3 O Ring 1 68 O Ring 2 82 Guide ring 1 91 O Ring 1 92 O Ring 1 8 Gasket 2 2 16 Diaphragm 1 1 47 U ring 1 1 50 O Ring 1 1 53 O Ring 1 1 8 Gasket 2 2 29 Diaphragm 1 1 47 U ring 1 1 53 O Ring 1 1 N OF PIECES I N I N TR DN POS DESCRIPTION Slam shut covers IN TR IN I N Fig M I N TR Reduced head Versions DVGW Fig N ...

Страница 56: ...CHNICAL MANUAL MT044 56 1 3 4 6 8 29 Diaphragm 1 1 1 60 O Ring 1 71 O Ring 1 84 O Ring 1 88 O Ring 1 90 O Ring 1 1 N OF PIECES MONITOR ER DN POS DESCRIPTION MONITOR ER Fig P DN 1 3 Fig R DN 6 8 Fig Q DN 4 ...

Страница 57: ...inal input diameter Pe inlet pressure Pa outlet pressure Works no Serial no Year of manufacture Type of fluid used Regulator cover diameter Gasket hardness 55 or 85 ShA Type of head for slam shut I N I N TR if installed Monitor if installed The no of the part position no Quantity desired 57 ...

Страница 58: ...TECHNICAL MANUAL MT044 58 NOTES ...

Страница 59: ...TECHNICAL MANUAL MT044 Ordering Information Part No PFN375DN50 40 PFN375DN50 45 ...

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